A cable bunching machine consists of multiple drive sections that operate continuously in coordination, including the pay-off, capstan, bow/flyer, reel/drum, and other cable processing units. When the existing control system becomes outdated or no longer meets operational requirements, the retrofit involves more than simply replacing the drives. The electrical control cabinet, control system, communication network, and drive sections must be redesigned and integrated as a complete system.
We have recently completed a complete control system retrofit for a cable bunching machine, including the design and installation of a new electrical control cabinet. The upgraded system uses Parker drives in combination with a Siemens PLC to control and coordinate the various drive sections of the machine.
Complete Electrical and Control System Retrofit for the Cable Bunching Machine
Rather than simply replacing individual components, the project was carried out as a complete retrofit of the machine’s control system.
A new electrical control cabinet was designed and installed, incorporating the required protection devices, control power supplies, contactors, relays, terminals, and other control components. The AC drives and DC Drive were reorganized and integrated within the cabinet to create a coordinated control system that is easier to operate and maintain.
A key aspect of the project was to configure the drive system according to the specific requirements of each machine section, rather than applying the same drive solution across the entire production line.
Parker DC590P 270A for Bow/Flyer Drive Control
The Bow/Flyer is one of the key drive sections of a cable bunching machine and requires stable and reliable control of the DC motor.
In this project, the Bow section is equipped with a Parker DC590P 270A DC Drive for controlling the motor.
Selecting the DC590P for this high-power drive section allows the system to continue utilizing the existing DC motor while upgrading the control system to a new platform, without requiring a complete replacement of the motor and mechanical drive system.
This is also an important consideration in cable bunching machine retrofit projects using DC motors: the control system can be upgraded while retaining the existing mechanical system and DC motor, provided that they remain suitable for the machine’s operating requirements.
Parker AC20 for the Remaining Drive Sections
The other drive sections of the machine are equipped with Parker AC20, providing AC motor speed control for the respective machine sections.
The machine consists of multiple coordinated sections, including:
- Pay-off – supplies the cable.
- Capstan – pulls and maintains the cable movement.
- Bow/Flyer – performs the cable bunching operation.
- Reel/Drum – takes up the finished cable.
- Tapping Unit (2N) – performs light twisting before the cable proceeds to the white tape wrapping section.
- Other downstream drive sections within the production line.
With multiple motors operating in coordination, centralized control through the PLC allows the different machine sections to operate according to the required process sequence and synchronization, rather than operating independently.
Parker AC20 Communication via PROFINET with Siemens S7-1200 G2
One of the key technical features of the project is the integration of the Parker AC20 drives with a Siemens S7-1200 G2 PLC via PROFINET.
Instead of using separate hardwired control signals for each drive, the system uses the PROFINET network for data exchange between the PLC and the AC20 drives.
Data Groups Managed in the Control Program
The control program can be structured to manage the following data groups:
- RUN/STOP commands
- Forward/Reverse control
- Speed reference
- Actual speed feedback
- Drive status
- Warning and Fault status
- Other control signals required for coordination between the different machine sections.
This is particularly important for a cable bunching machine, where multiple drive sections must operate in coordination according to the same production process. The Siemens S7-1200 G2 PLC serves as the central control system, while the Parker AC20 drives control the motors in their respective machine sections.
Completely New Parker Control Cabinet Design
The completed control cabinet shows that the entire electrical system has been reorganized into dedicated sections for:
Power Supply → Protection Devices → DC Drive → AC Drives → PLC → Communication Devices → Relays/Contactors → Terminals
The new cabinet design is not simply intended to improve the appearance of the system, but focuses on system integration, wiring accessibility, maintenance, and future expansion.
By integrating Parker AC20, Parker DC590P, and Siemens PLC into a unified control system, the drive sections can be managed in a more centralized and structured manner.
Key Highlights of the Cable Bunching Machine Retrofit Project
The project combines DC drive technology, AC drive technology, and industrial communication, including:
Parker DC590P 270A
→ Controls the DC motor of the Bow/Flyer section.
Parker AC20
→ Controls the remaining AC motor drive sections.
PROFINET
→ Provides communication between the AC20 drives and the central control system.
Siemens S7-1200 G2
→ Provides centralized control and coordination of the entire machine.
New Electrical Control Cabinet
→ Complete redesign and installation of the machine’s electrical control system.
More Than Drive Replacement – A Complete Control System Retrofit
For cable bunching machines that have been in operation for many years, a retrofit involves more than replacing individual drives. The upgraded system must address drive control, speed regulation, coordination between multiple motors, control signals, and PLC-to-drive communication as an integrated solution.
For this project, we completed a full retrofit of the machine’s control system and installed a completely new electrical control cabinet, using the Parker DC590P for the high-power DC drive section, Parker AC20 for the AC drive sections, and PROFINET communication with a Siemens S7-1200 G2 PLC.
This approach is suitable for cable bunching machines, wire bunching machines, cable twisting machines, and production lines with multiple coordinated drive sections, particularly where the objective is to modernize the control system while retaining suitable existing motors and mechanical equipment.
Contact Us for Cable Bunching Machine Retrofit Solutions
If you are looking to retrofit a cable bunching machine, wire bunching machine, or upgrade an industrial drive control system, Parker Vietnam – Viet Technical Engineering Co., Ltd. provides solutions covering site assessment, drive selection, electrical control cabinet design, PLC programming, communication configuration, installation, and commissioning.
We provide technical consultation for solutions using Parker DC Drives, Parker AC Drives, Siemens PLCs, and industrial communication networks such as PROFINET and PROFIBUS, depending on the actual machine configuration.
Parker Vietnam – Viet Technical Engineering Co., Ltd.
- 🌐 Website: parkervietnam.com
- 📞 Hotline/WhatsApp: +84 908 353 714
- 📧 Email: info@kythuatviet.vn
- 🔧 Technical consultation, Drive selection, and machine retrofit solutions
- 🏭 Electrical control cabinet design, installation, and control system upgrades
- 🚚 Genuine Parker products with nationwide delivery support
Contact Parker Vietnam for technical consultation and a suitable retrofit solution for your existing machine.
